Maintenance Service Procedure Document For AMC: Scada &telecom System For Agcl Gas Pipeline Network

This document is exclusive property of ABB Limited.
It is to be used only for the purpose which it is lent and must not be copied or used in anyway detrimental to the interest of this company and subject to return on demand.
SCADA &TELECOM SYSTEM FOR AGCL GAS PIPELINE NETWORK .
Maintenance Service Procedure Document for AMC
MAINTENANCE SERVICE PROCEDURE DOCUMENT

Project: SCADA &TELECOM SYSTEM FOR AGCL GAS PIPELINE NETWORK.
Title FOR AMC
Doc no. Lang: en Rev no. Page 1
ABB INDIA Limited 3BYN496024-JJBC Date: 14/10/19 01 Pages 17
This document is exclusive property of ABB Limited. It is to be used only for the purpose which it is lent and must not be copied or used in anyway detrimental to the interest of this company and subject to return on demand.
CSR:
With Ref to the comments vide
TE E-mail for AGCL _ Trial run punch points status Dated: 10.10.2019
ABB Document Identify: 3BYN496024-Txxx Dated: 27.09.2019
Doc Title: Maintenance Service Procedure Document for AMC Rev no. – 00
Our Reply/ Response is as follows:
Sl Comments from TE-IN/AGCL Response by

No ABB
1 ABB shall submit visit plan details in proper format with sign & stamp of project manager & concern engineer. This Noted &
shall be submitted in two sets of hard copies. Format should have following Format
1. hard copy in form of booklet. attached
2. add column- visit date, visitor sign, Problem identify, Problem attended and remark.
3. Format should have project no, PO no, logo of client, project name etc.
2 Noted &
Incorporated
Please refer
Cloud Mark,
TE Comments: This shall be within 48 Hrs as per AMC conditions Page no 9 of
19

Title FOR AMC
3 Noted &
Incorporated
Please refer
Cloud Mark,
TE Comments: All the softwares up gradation of system shall be in ABB scope of work, refer AMC details Page no 6 of
19
4 Page 7 of 17 Noted &

Incorporated
Please refer
Cloud Mark,
Page no 9 of
TE Comments: this statement is not acceptable. ABB shall use spare but after repair of faulty hardware, same shall be 19
put back in service and used spare shall be once again kept in spare for future.
Table of content

Title FOR AMC
1. Introduction.................................................................................................…….. 3
1.1 Project Introduction 3
1.2 Project Objective...............................................................................................................3
2. Introduction and Scope of maintenance Service......................................................4
2.1 Services Covered under scope of Maintenance service...............................................4
3. Preventive Maintenance Services……………………………………………………………………………5
3.1Half Yearly PM procedure for 74 TE, Major Consumer & PRS under New SCADA Scope…….6
3.2Half Yearly PM procedure for MCS…………………………………………………………………………………….6
3.3Tools & Testing equipment………………………………………………………………………………………………..6
4.Breakdown Maintenance Services……………………………………………………………………………..7

4.1 Breakdown Maintenance Procedure………………………………………………………………………………..7.
5. Report Submission during AMC……………………………………………………………………………………8
5.1 Monthly Report……………………………………………………………………………………………………………..8
5.2 Quarterly Report……………………………………………………………………………………………………………8
6. Exclusion……………………………………………………………………………………………………………………8

Title FOR AMC
1. INTRODUCTION
1.1. Project Introduction

Assam Gas Company Ltd., Duliajan has been in the business of transporting high pressure and low pressure natural gas, through
its transmission and distribution network covering five districts of upper Assam, India to several key segments
The gas is collected presently from sources of OIL and ONGCL. However, gas from other producers may also be injected into
AGCL network as and when available, the compressed gas is transported by dedicated and common carriers lines to industries
such as Brahmaputra Valley Fertilizer Corporation Ltd (BVFCL), Assam Petrochemical Limited (APL), Namrup Thermal Power
Station (NTPS) and uncompressed natural gas to Lakwa thermal power station (LTPS) and Power Plant of NEEPCO. The company
also supplies low pressure natural gas to over 365 tea factories spread over five districts of Upper Assam.
Assam gas company Ltd. Duliajan is planning to build a supervisory control and data acquisition system (SCADA) and
Telecommunication system for acquiring, monitoring and controlling the process data from single location for existing Gas
pipeline network spread over five districts of upper Assam. Hereafter the project is called as "SCADA AND TELECOM SYSTEM
FOR AGCL GAS PIPELINE NETWORK”
TractebelEngineering Private Limited (TE-IN) has been appointed by AGCL for Consultancy service for setting up of SCADA and
Telecom system for gas pipeline network of AGCL
1.2. Project Objective

The objective of setting up a SCADA system is to monitor & control the gas flow to the tea factories as per agreed quantity &
also to permit the customers to withdraw more gas within 150% of the agreed quantity when there is excess gas available in the
network. In case of major consumer, SCADA system is to monitor the volume & pressure of the gas at receiver’s as well as
consumer’s end point.

Title FOR AMC
2. Introduction and Scope of Maintenance Service

Entire network SCADA system will be under defects liability period for 1 year and thereafter will be under the scope of comprehensive
maintenance service for 4 years. As a part of Defects liability period + AMC, ABB will deploy teams that will carry out the Preventive
Maintenance Services & Breakdown Maintenance. Broadly the infrastructure consists of all hardware/software including field instrumentation,
RTUs, SCADA systems, servers, workstations, equipment, UPS System etc.
This will be a comprehensive AMC and will include replacement of defective parts / modules / cards / software/hardware, as part of main
contract, required for smooth operation of SCADA system at Various installations of Assam Gas Company Limited.
The procedures for each of the services offered are detailed in this document.
2.1Services Covered under scope of Maintenance service
Software Updates
Supply of software debugging/up gradation is covered during 4 years AMC period.
Server and network management activities

The activities related to the server will be carried out during the Preventive Maintenance Procedure in MCS.
Status and Performance Monitoring

The Status and Performance Monitoring of all the Servers provided under the project shall be performed.
Application of Patches/ Bug Fixes
The Application of Patches/Bug Fixes for current windows operating system software if available free of cost to ABB will be done after
taking prior approval for the same from Assam Gas Company Limited.

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Implementing OS Hardening to enhance system security
All the required OS Hardening for security is already implemented. However, the same shall be ensured while replacing the faulty
hardware.
Network connectivity, routing /access control:

Network outages and routing issues will be communicated to and followed-up with Assam Gas Company Limited.
Back-up Management as per decided policy:

The Back-up of SCADA Database and Graphics will be taken on Half Yearly basis in the external Hard Disk.
Actions for Virus Protection:

The Anti-Virus software for all ABB supplied IT Hardware in SCADA project has been supplied by ABB India Ltd.
3. Preventive Maintenance Services

The preventive maintenance services will be carried out by ABB for the supplies made as per the contract. The schedule for the preventive
maintenance service, check list & report is part of this document.
During the maintenance visit ABB engineer shall co-ordinate with the SCADA I/C – Assam Gas Company Limited. discuss the details of the
activities carried out and the problem faced by him. The Preventive Maintenance (PM) shall be done half yearly basis.
ABB will conduct PM every half year through use of System/Field Instrument diagnostics and diagnostics information of the hardware
components of SCADA system.
Calibration of the instruments shall be undertaken on yearly basis or as recommended by OEM. In cases where there is a replacement of faulty
instrument the same shall calibrated before installation.

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L;,ZThe PM procedure is classified in the following categories depending upon the location.
3.1 Half Yearly PM procedure for 74 TE, Major Consumer & PRS under New SCADA Scope
The preventive maintenance procedure for the facilities includes procedure for the RTU/Instrumentation /UPS as per applicability.
The PM at each of the installation shall be carried out as per the procedure indicated in Appendix - 1 (PM Procedure and Checklist for
respective Location). Upon Completion of the PM the checklist for the same is to be provided to AGCL SCADA I/C. In case preventive
maintenance cannot be carried out at a location in line with the schedule, same shall be brought out in the preventative maintenance checklist
and reports and same shall be rescheduled preferably within the same week.
3.2 Half Yearly PM procedure for MCS

The preventive maintenance procedure for MCS includes procedure for the SCADA Servers, GPS, HMIs & UPS, Battery bank. The PM at MCS is
to be carried out as per the procedure indicated in Appendix - 1 (Half Yearly PM Procedure and Checklist for MCS). Upon Completion of the
PM, the checklist for the same is to be provided to AGCL SCADA I/c. In case a successful Preventive maintenance cannot be carried out at MCS
same should be brought out in the PM checklist and reports. It should be rescheduled preferably with the same week or in next week.
3.3 Tools & Testing equipment

ABB engineers will have a set of required tools. For Break Down as well as for Preventative maintenance jobs they shall go along with these
tools. Relevant specialized / special tools shall be available with ABB engineer to perform the required maintenance task.

Title FOR AMC
4. Breakdown Maintenance Services

The breakdown maintenance services are provided to ensure that the breakdown in any of the location is attended within 48 hours on the
receipt of such information from owner. The procedure to be followed for breakdown maintenance is explained below.
4.1 Breakdown Maintenance Procedure

The calls for the breakdown in any system are logged manually at the MCS, these calls are assigned to the maintenance engineer. ABB
engineers shall attend the calls and on completion the same shall be informed to the ASSAM GAS COMPANY LIMITED SCADA I/C. In case the
calls could not be attended or solved it will be informed to the ASSAM GAS COMPANY LIMITED SCADA I/C. In such cases the call is kept open till
the same is resolved.
The procedure for attending the breakdowns/equipment failures is based on the troubleshooting procedures mentioned in the OEM manuals.
The maintenance engineers will follow this document for trouble shooting of the failed device/ equipment. In general following are the steps
for the attending and resolving the breakdown/failure call.
The breakdown maintenance procedure primarily includes following steps:
 Identify the problem

 If problem is with the hardware, then attend & rectify the same
 If the problem cannot be solved or concluded, then replace the hardware.
 If the problem is with software, then record the problem and resolve the same by reinstalling or restoring from the backup as
applicable.
 If the problem is related to the equipment/instrument not under ABB scope of maintenance service, then inform to the ASSAM GAS
COMPANY LIMITED SCADA I/C for rectification.
In case the failed devices are replaced with a spare, the faulty one will be sent for repair. Once it is repaired the same device shall be put back
in service and used spare shall be once again kept in spare for future.

Title FOR AMC
5. Report Submission during AMC
5.1 Monthly Report

The monthly report will be submitted in the first week of every month as per the format in hardcopy. The report shall be submitted to the
SCADA I/c.
5.2 Quarterly Report

The quarterly report will be submitted in the first week of each quarter beginning as per the format in Hard Copy. The hardcopy will consist of
 Quarterly Breakdown Report.

 PM Completion Checklist.
The reports will be submitted by the ABB Maintenance Engineer.
6. Exclusions
The following shall remain out of scope of this contract.
a. Printer consumables like printer cartridges, paper after completion of defective liabilities period.
b. All cable: Repair, replacement need arising due to physical damage like cut, damage, and rupture due to reasons not attributable to ABB.
c. Damage on account of rodent /reptile entry.
d. Batteries of UPS after defect liability period, however scope covers maintenance of UPS.
e. Replacement of any equipment or part damaged or failed due to lightning, physical damages reasons not attributable to ABB, short circuit
and power surge from AGCL source.
f. Faulty/Non-working instruments due to change in process parameters as provided during engineering site survey and process parameters
are beyond the instrument range.

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APPENDIX -I
PM PROCEDURE

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PM PROCEDURE-MCS
Maintenance Activity Procedure Status (C/NC) Remarks
UPS:
1.Inspection (Physical + Clean the panel inside & outside

Cleanness)

2. Cooling Fan Check that the cooling fans are running smoothly & it is
not making noise.
3. Environment of UPS Check for environment in the UPS room. If AC is not

room workingin the UPS room immediately report to
concerned officials of AGCL
4. Mains Input Voltage (1 Check the input incoming voltage in Display unit of UPS
phase or 3 phase) in Volt and record it. It should be as per specifications.
5. Mains Input Current (1 Check the input incoming current in Display unit and
phase or 3 phase) in record it. It should be below the UPS rated current.
Amps
6. Check Auxiliary input Check the Auxiliary voltage in Display unit and record it.
voltage It should be as per specifications.
7. Check inverter Voltage Check the inverter voltage in Display unit of UPS and
record it. It should be as per specifications.
8. Check the UPS Output Check the output voltage in Display unit of UPS and

Title FOR AMC
Voltage record it. It should be as per specifications.
9. Output Current in Check the output current in Display unit of UPS and
Amps record it. It should be as per specifications.
10. Battery Check the battery charging & discharging current in UPS
Charging/Discharging display and record it.
Current in Amps
11.Battery voltage and Check battery voltage & current with mains in off
current (when mains in condition in Display unit of UPS.
Off condition)
12. Battery voltage and Check battery voltage & current with mains in off
current (when mains in condition in Display unit of UPS and record it.
Off Condition)
13. Battery Voltage and Check battery voltage & current after putting back to
Current after putting mains input in Display unit of UPS and record it.
back to mains Input
Servers :
1. Cabinet health check a. Check the cabinets are free from dust and other
for Server cabinets foreign materials. Clean the Cabinets.

Title FOR AMC
b. Press the door limit switch and check whether the fans
and lights are working properly.
2. Server Performance a. Open the task manager of the server and check for any
excess utilization in the server resources.
3. Unwanted software’s a. Go to Add/Remove programs in control panels and

check that unwanted software’s are not installed. If any
unwanted software is found, then same should be
bought out to ASSAM GAS COMPANY LIMITED. notice
and accordingly removed from the servers
4.Software / Archived a. Check the HDD space consumed by the history

Data Backup accumulated in the SCADA servers and identify the need
for the archiving. If needed, archive all the data to the
media and put an identification on the same with
a. Take periodic backup every 6 month as per the backup

5.Software / Archived procedure indicated in the user guides for the SCADA /
Data Backup RTU and other software’s as applicable.

6. Unwanted folders in
a. Check if unwanted folders are created in the desktop
Server or partitioned Drives. Delete the unwanted folder if
any.
PM PROCEDURE-MAJOR CONSUMER LOCATION NAME: BVFCL DATE: 10.08.2020

Title FOR AMC
FLOW COMPUTER AND MODEM
Flow Computer a. Check the Flow computer cabinet are free from dust
and other foreign materials. Clean the Cabinets. OK
b. Check the cable tightness of the Flow Computer OK
c. Check the incoming supply of the Flow computer 12VDC
d. Check the connection of the modem and its signal OK

strength
e. Need to take the program backup of the RTU and OK
need to be stored in the external HDD
g. Check the communication status of Flow computer OK
with SCADA

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PM PROCEDURE – PRS (3NOS)
FILTARATION SKID
Manual valves at inlet header and at a.Check the tightness of the stud bolts
Filter’s inlet and outlet.
a. Smear a light coating of grease to
the sealing and mating faces for
protection from corrosion
Pressure Gauge at inlet header a. Clean the gauges exteriors and
housing with Lint free soft cloth.
Pressure control valve active a. Check the set point tuning
monitor
Slam shut valve and creep relief a. Check the set point tuning
valve
b. Inspect appearance for obvious
damage and external tightness.
c. clean parts such as diaphragm,
valve plug and O-ring. Other O-
rings
are needed to be checked
Filter Element a. Check the condition of filter

Title FOR AMC
element. Clean the filter and

remove the elements from the
case and bottom of the case
should be clean from all solids
and liquids.
Pressure regulator a. Ensure that there is no leakage
on the regulator and tubing
connections using soap solution.
b. Observe the outlet pressure
gauge to make sure that the
desired outlet pressure is
stabilized.
c..Clean the regulator and pilot and
check the seat, diaphragm, O-rings
and other soft parts.
d..Check the other parts of the

regulator to ensure that they are in
good working condition. Change the
worn out parts
e..Ensure the pipeline system is
clean and free of foreign materials.
Note : C means Completed/ NC means Not Completed

Title FOR AMC

Maintenance Service Procedure Document For AMC: Scada &telecom System For Agcl Gas Pipeline Network

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SCADA &TELECOM SYSTEM FOR AGCL GAS PIPELINE NETWORK .

Maintenance Service Procedure Document for AMC

MAINTENANCE SERVICE PROCEDURE DOCUMENT

ABB Document Identify: 3BYN496024-Txxx Dated: 27.09.2019

Our Reply/ Response is as follows:

Sl Comments from TE-IN/AGCL Response by

MAINTENANCE SERVICE PROCEDURE DOCUMENT

4 Page 7 of 17 Noted &

MAINTENANCE SERVICE PROCEDURE DOCUMENT

3.2Half Yearly PM procedure for MCS…………………………………………………………………………………….6

3.3Tools & Testing equipment………………………………………………………………………………………………..6

4.Breakdown Maintenance Services……………………………………………………………………………..7

MAINTENANCE SERVICE PROCEDURE DOCUMENT

1.1. Project Introduction

1.2. Project Objective

MAINTENANCE SERVICE PROCEDURE DOCUMENT

2. Introduction and Scope of Maintenance Service

2.1Services Covered under scope of Maintenance service

Server and network management activities

Status and Performance Monitoring

Application of Patches/ Bug Fixes

MAINTENANCE SERVICE PROCEDURE DOCUMENT

Implementing OS Hardening to enhance system security

Network connectivity, routing /access control:

Back-up Management as per decided policy:

Actions for Virus Protection:

3. Preventive Maintenance Services

MAINTENANCE SERVICE PROCEDURE DOCUMENT

3.2 Half Yearly PM procedure for MCS

3.3 Tools & Testing equipment

MAINTENANCE SERVICE PROCEDURE DOCUMENT

4. Breakdown Maintenance Services

4.1 Breakdown Maintenance Procedure

The breakdown maintenance procedure primarily includes following steps:

 Identify the problem

MAINTENANCE SERVICE PROCEDURE DOCUMENT

5. Report Submission during AMC

5.1 Monthly Report

5.2 Quarterly Report

 Quarterly Breakdown Report.

MAINTENANCE SERVICE PROCEDURE DOCUMENT

MAINTENANCE SERVICE PROCEDURE DOCUMENT

Maintenance Activity Procedure Status (C/NC) Remarks

1.Inspection (Physical + Clean the panel inside & outside

3. Environment of UPS Check for environment in the UPS room. If AC is not

MAINTENANCE SERVICE PROCEDURE DOCUMENT

Voltage record it. It should be as per specifications.

MAINTENANCE SERVICE PROCEDURE DOCUMENT

3. Unwanted software’s a. Go to Add/Remove programs in control panels and

4.Software / Archived a. Check the HDD space consumed by the history

a. Take periodic backup every 6 month as per the backup

PM PROCEDURE-MAJOR CONSUMER LOCATION NAME: BVFCL DATE: 10.08.2020

MAINTENANCE SERVICE PROCEDURE DOCUMENT

FLOW COMPUTER AND MODEM

b. Check the cable tightness of the Flow Computer OK

c. Check the incoming supply of the Flow computer 12VDC

d. Check the connection of the modem and its signal OK

MAINTENANCE SERVICE PROCEDURE DOCUMENT

PM PROCEDURE – PRS (3NOS)

MAINTENANCE SERVICE PROCEDURE DOCUMENT

element. Clean the filter and

d..Check the other parts of the